U.S. patent number 10,886,684 [Application Number 16/288,454] was granted by the patent office on 2021-01-05 for bonding method for conductor of electric wire and electric wire.
This patent grant is currently assigned to YAZAKI CORPORATION. The grantee listed for this patent is Yazaki Corporation. Invention is credited to Naoki Ito, Yasunori Nabeta, Tomoya Sato, Kazuhide Takahashi.
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United States Patent |
10,886,684 |
Sato , et al. |
January 5, 2021 |
Bonding method for conductor of electric wire and electric wire
Abstract
A bonding method for a conductor of an electric wire including a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length. The bonding method includes bonding the strands to each
other, the strands being spaced apart from the sheath by a
predetermined length. An outer diameter of a middle portion of the
conductor between a bonded portion and a portion covered with the
sheath gradually decreases toward the bonded portion. A maximum
value of an intersection angle between an upper surface of the
bonded portion or a longitudinal direction of the electric wire and
the strands of the middle portion is smaller than a predetermined
angle. The predetermined angle is an angle at which breakage of the
strands is prevented when the bonding is performed.
Inventors: |
Sato; Tomoya (Shizuoka,
JP), Takahashi; Kazuhide (Shizuoka, JP),
Ito; Naoki (Shizuoka, JP), Nabeta; Yasunori
(Shizuoka, JP) |
Applicant: |
Name |
City |
State |
Country |
Type |
Yazaki Corporation |
Tokyo |
N/A |
JP |
|
|
Assignee: |
YAZAKI CORPORATION (Tokyo,
JP)
|
Family
ID: |
1000005284926 |
Appl.
No.: |
16/288,454 |
Filed: |
February 28, 2019 |
Prior Publication Data
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|
|
Document
Identifier |
Publication Date |
|
US 20190273355 A1 |
Sep 5, 2019 |
|
Foreign Application Priority Data
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|
|
|
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Mar 1, 2018 [JP] |
|
|
2018-036345 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H01R
4/185 (20130101); B23K 20/004 (20130101); B23K
20/10 (20130101); H01R 4/187 (20130101); H01R
43/0207 (20130101); H01L 2224/85205 (20130101); B23K
2101/38 (20180801) |
Current International
Class: |
H01R
4/18 (20060101); H01R 43/02 (20060101); B23K
20/10 (20060101); B23K 20/00 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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2 650 984 |
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Oct 2013 |
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EP |
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2005-222849 |
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Aug 2005 |
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JP |
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2009-231079 |
|
Oct 2009 |
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JP |
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2011-82127 |
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Apr 2011 |
|
JP |
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2014-154443 |
|
Aug 2014 |
|
JP |
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2015-135742 |
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Jul 2015 |
|
JP |
|
Primary Examiner: Nguyen; Chau N
Attorney, Agent or Firm: Sughrue Mion, PLLC
Claims
What is claimed is:
1. An electric wire including a conductor formed of a plurality of
strands and a sheath covering the conductor such that the conductor
is exposed by a predetermined length, the electric wire comprising:
a bonded portion spaced apart from the sheath by the predetermined
length, in which the plurality of strands of the conductor, which
are bonded to each other, are exposed from the sheath; and a middle
portion of the conductor formed between the bonded portion and the
sheath, wherein an outer diameter of the bonded portion is smaller
than an outer diameter of the conductor in a portion covered with
the sheath, and an outer diameter of the middle portion of the
conductor gradually decreases toward the bonded portion from the
portion of the conductor covered with the sheath, a maximum value
of an intersection angle between an upper surface of the bonded
portion or a longitudinal direction of the electric wire and the
plurality of the strands in the middle portion of the conductor is
smaller than a predetermined angle, the predetermined angle is an
angle at which breakage of all the plurality of the strands in the
middle portion due to formation of the bonded portion is prevented,
and wherein the predetermined angle has a value that is less than a
value .theta.b, calculated according to the following formula:
.theta.b=cos.sup.-1(1/(1+ ) wherein indicates a distortion of a
strand of the plurality of strands having the maximum value of the
intersection angle.
2. The electric wire according to claim 1, wherein the bonded
portion is formed in a state in which ultrasonic bonding is
completed using an anvil and a horn, and a distance between the
bonded portion and the sheath of the electric wire is shorter than
a length of the plurality of strands when the plurality of strands
are vibrated in a primary mode by ultrasonic vibration.
3. The electric wire according to claim 1, wherein the strand of
the plurality of strands having the maximum value of the
intersection angle is a strand positioned on an outer periphery of
the middle portion.
Description
CROSS REFERENCE TO RELATED APPLICATION
This application is based upon and claims the benefit of priority
from the prior Japanese Patent Application No. 2018-036345 (filing
date: Mar. 1, 2018), the entire contents of which are incorporated
herein by reference.
BACKGROUND
Technical Field
The present invention relates to a bonding method for a conductor
of an electric wire and an electric wire, and in particular, to a
method for bonding a plurality of strands to each other in a part
of a conductor of an electric wire.
Related Art
Conventionally, technology has been known in which a part of a
conductor of an electric wire is clamped between an anvil and a
horn in a vertical direction and a plurality of strands
constituting the conductor are bonded to each other by ultrasonic
vibrating the horn in a longitudinal direction of the electric wire
(front rear direction) (see JP 2015-135742 A).
On the other hand, when the strands are bonded to each other by
ultrasonic bonding using an anvil and a horn as in the prior art,
each of the strands is compressed in a bonded portion in which the
strands are ultrasonically bonded to each other, that is, a portion
of the strands clamped between the anvil and the horn.
Due to the compression, the strands positioned in a middle portion
existing between the sheath and the bonded portion in the
longitudinal direction (front-rear direction) of the electric wire
are pulled (tensile stress is generated in each strand).
Therefore, when the value of the tensile stress occurring in the
strands in this manner becomes large, the strand may be broken when
ultrasonic bonding is performed.
The strand breakage described above may also occur when the strands
are joined to each other by a method other than ultrasonic
joining.
SUMMARY
The present invention has been made in view of the above problems,
and it is an object of the present invention to provide a bonding
method for a conductor of an electric wire and the electric wire, a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length, which prevent occurrence of strand breakage when a
plurality of strands of the electric wire are bonded to each
other.
A bonding method according to first aspect of the present invention
is a bonding method for a conductor of an electric wire including a
conductor formed of a plurality of strands and a sheath covering
the conductor such that the conductor is exposed to a predetermined
length, the bonding method bonding the plurality of strands of the
electric wire to each other. The method includes bonding the
strands of the conductor exposed from the sheath to each other, the
strands being spaced apart from the sheath by a predetermined
length. An outer diameter of a middle portion of the conductor
between a bonded portion formed by bonding the strands of the
conductor to each other and a portion covered with the sheath
gradually decreases toward the bonded portion from the portion of
the conductor covered with the sheath. A maximum value of an
intersection angle between an upper surface of the bonded portion
or a longitudinal direction of the electric wire and the strands of
the middle portion of the conductor is smaller than a predetermined
angle. The predetermined angle is an angle at which breakage of the
strands is prevented when the bonding is performed.
The bonded portion may be formed by performing ultrasonic bonding
using an anvil and a horn. The anvil and the horn may be provided
with an inclined surface contacting a portion of the middle portion
on a side of the bonded portion throughout a predetermined
length.
The bonded portion may be formed by performing ultrasonic bonding
using an anvil and a horn. When ultrasonic bonding of the conductor
is performed by clamping a part of the conductor exposed from the
sheath between the anvil and the horn throughout a predetermined
length and ultrasonically vibrating the horn, a distance from the
anvil or the horn to the sheath of the electric wire may be shorter
than a length of the strands when the strand vibrates in a primary
mode by ultrasonic vibration.
After the bonded portion is formed, a bonding state of the bonded
portion may be inspected by performing at least one of allowing a
fluid having a flow rate exceeding a predetermined speed to flow to
the bonded portion and applying an acceleration exceeding a
predetermined magnitude to the bonded portion.
An electric wire according to second aspect of the present
invention includes a conductor formed of a plurality of strands and
a sheath covering the conductor such that the conductor is exposed
to a predetermined length. The electric wire includes a bonded
portion spaced apart from the sheath by a predetermined length, in
which the strands of the conductor exposed from the sheath are
bonded to each other, and a middle portion of the conductor formed
between the bonded portion and the sheath. An outer diameter of the
bonded portion is smaller than an outer diameter of the conductor
in the portion covered with the sheath, and an outer diameter of
the middle portion of the conductor gradually decreases toward the
bonded portion from a portion of the conductor covered with the
sheath. A maximum value of an intersection angle between an upper
surface of the bonded portion or a longitudinal direction of the
electric wire and the strands of the middle portion of the
conductor is smaller than a predetermined angle. The predetermined
angle is an angle at which breakage of all the strands of the
middle portion due to formation of the bonded portion is
prevented.
The bonded portion may be in a state in which ultrasonic bonding is
completed using the anvil and the horn. A distance between the
bonded portion and the sheath of the electric wire may be shorter
than a length of the strands when the strands are vibrated in a
primary mode by ultrasonic vibration.
A bonding method for a conductor of an electric wire and the
electric wire, a conductor formed of a plurality of strands and a
sheath covering the conductor such that the conductor is exposed to
a predetermined length, according to aspects of the present
invention prevent occurrence of strand breakage when a plurality of
strands of the electric wire are bonded to each other.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a perspective view illustrating an electric wire obtained
by a bonding method for a conductor of an electric wire according
to an embodiment of the present invention;
FIG. 2 is a diagram illustrating a bonding method for a conductor
of an electric wire according to an embodiment of the present
invention;
FIG. 3A is a diagram illustrating a bonding method for a conductor
of an electric wire according to an embodiment of the present
invention;
FIG. 3B is a diagram viewed along arrow IIIB of FIG. 3A;
FIG. 3C is a cross-sectional view taken along IIIC-IIIC of FIG.
3A;
FIG. 4 is a diagram illustrating an electric wire with a terminal
in which a terminal is fixed in an electric wire obtained by a
bonding method for a conductor of an electric wire according to an
embodiment of the present invention;
FIG. 5 is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 6 is a perspective view illustrating an electric wire obtained
by a bonding method for a conductor of an electric wire according
to a modification;
FIG. 7A is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 7B is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 8A is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 8B is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 9A is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 9B is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 10A is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 10B is a diagram illustrating a bonding method for a conductor
of an electric wire according to a modification;
FIG. 11A is a diagram illustrating an electric wire in which some
of strands are not bonded to a bonded portion and a state in which
strands that are not bonded to the bonded portion (straggling
strands) extend along the bonded portion;
FIG. 11B is a diagram illustrating an electric wire in which some
of strands are not bonded to a bonded portion and a state in which
strands that are not bonded to the bonded portion are separated
from the bonded portion and stretch out;
FIG. 12A is a diagram illustrating an electric wire in which some
of strands are not bonded to a bonded portion and a state in which
strands that are not bonded to the bonded portion are separated
from the bonded portion and stretch out;
FIG. 12B is a side view of FIG. 12A;
FIG. 13A is a diagram illustrating an electric wire in which some
of strands are not bonded to a bonded portion and a state in which
strands that are not bonded to the bonded portion are separated
from the bonded portion and stretch out;
FIG. 13B is a side view of FIG. 13A;
FIG. 14A is a diagram illustrating an electric wire in which some
of strands are not bonded to a bonded portion and a state in which
strands that are not bonded to the bonded portion are separated
from the bonded portion and stretch out;
FIG. 14B is a side view of FIG. 14A;
FIG. 15 is a diagram illustrating a modification of FIGS. 11A to
14B;
FIG. 16 is a diagram illustrating a modification of FIGS. 11A to
14B; and
FIG. 17 is a diagram illustrating a modification of FIGS. 11A to
14B.
DETAILED DESCRIPTION
An electric wire 1 manufactured by a bonding method for a conductor
of an electric wire according to an embodiment of the present
invention will be described below with reference to FIGS. 1 and
2.
For convenience of description, the longitudinal direction of the
electric wire 1 is defined as the front-rear direction, one
predetermined direction orthogonal to the front rear direction is
defined as the vertical direction, and a direction orthogonal to
the longitudinal direction and the vertical direction is defined as
a width direction.
The electric wire 1 includes a conductor 3 and a sheath 5. The
conductor 3 is formed of a plurality of strands 7. The sheath 5
covers the conductor 3 such that the conductor 3 is exposed to a
predetermined length. The conductor 3 is exposed to the
predetermined length in, for example, a front end of the electric
wire 1.
A bonded portion 9 is formed in the electric wire 1. The bonded
portion 9 is spaced apart from the sheath 5 by a predetermined
distance in the front rear direction and is formed to have a
predetermined length in the front rear direction. In the bonded
portion 9, the strands 7 of the conductor 3A which is exposed
(exposed conductor) (see FIGS. 3A to 3C; separate strands are not
illustrated in FIGS. 1 and 2) are bonded to each other by
ultrasonic bonding (ultrasonic treatment) using an anvil 11 and a
horn 13. The conductor 3 becomes, for example, a single wire in the
bonded portion 9, for example.
In addition, a middle portion 15 is formed in the electric wire 1.
The middle portion 15 is formed between the bonded portion 9 and
the sheath 5 in the front rear direction. In the middle portion 15,
the strands 7 of the exposed conductor 3A are not bonded to each
other, but in the vicinity of the bonded portion 9, the strands 7
may be bonded to each other due to the influence of the ultrasonic
bonding using the anvil 11 and the horn 13.
The bonded portion 9 is formed in a rectangular parallelepiped
shape (a square column shape), and the dimension thereof in the
width direction is greater than the dimension in the vertical
direction. In addition, when viewed in the front rear direction, a
portion of the conductor 3 covered with the sheath 5 has a circular
shape (see FIG. 3C).
The cross-sectional shape of the bonded portion 9 (the
cross-sectional shape taken along the plane orthogonal to the front
rear direction) is smaller than the cross-sectional shape of the
portion of the conductor 3 covered with the sheath 5. The
cross-sectional shape of the middle portion 15 gradually changes
from the circular shape of the portion covered by the sheath 5 to
the rectangular shape of the bonded portion 9.
When seen in the front-rear direction, the rectangular-shaped
bonded portion 9 is positioned inside the circular-shaped conductor
3 covered with the sheath 5, and the center of the conductor 3
covered with the sheath 5 and the center of the bonded portion 9
coincide with each other. In addition, the center of the conductor
3 covered with the sheath 5 and the center of the bonded portion 9
may be deviated from each other.
The outer diameter (the maximum outer diameter d1 illustrated in
FIG. 1 and the minimum outer diameter d2 illustrated in FIG. 2) of
the bonded portion 9 is smaller than the outer diameter d3 (see
FIG. 2) of the portion of the conductor 3 covered with the sheath 5
(more precisely, the portion of the conductor 3 at an end of the
sheath 5 at a position at which the conductor 3 starts to be
exposed).
The outer diameter of the middle portion 15 of the conductor 3
gradually decreases toward the bonded portion 9 from the portion of
the conductor 3 covered with the sheath 5 (toward the front side
from the rear side).
In the electric wire 1, the value x (see FIG. 2) of a length
dimension (a dimension in the front rear direction) of the middle
portion 15 is less than a value of a length dimension L (see
formula "f1" described below) required for the strands 7 to
resonantly vibrate in the primary mode between the anvil 11 (or the
horn 13) and the sheath 5 by ultrasonic vibration, the ultrasonic
vibration performed on the strands 7 to form the bonded portion 9.
The length dimension L will be described below.
In addition, in the electric wire 1, the maximum value .theta. of
the intersection angle between an upper surface of the bonded
portion 9 or the front and rear direction and the strands 7 of the
middle portion 15 of the conductor 3 is smaller than a
predetermined angle .theta.a. The upper surface of the bonded
portion 9 may be a lower surface of the bonded portion 9.
The intersection angle between the front-rear direction (the
central axis C1 of the electric wire 1) and the outer peripheral
surface 15A of the middle portion 15 may be adopted as the maximum
value .theta. of the intersection angle (see FIG. 2).
The maximum value .theta. of the intersection angle may be an angle
at which the breakage of all the strands 7 of the middle portion 15
due to ultrasonic bonding can be prevented. More specifically, the
maximum value .theta. of the intersection angle is an angle at
which a strand 7 intersecting at the angle of maximum value .theta.
with respect to the front rear direction among the strands 7 of the
middle portion 15 does not cause fatigue fracture even due to
compression of the strands 7 at the bonded portion 9 and ultrasonic
vibration during ultrasonic bonding. The maximum value .theta. of
the intersection angle and the predetermined angle .theta.a will be
described below.
As illustrated in FIG. 4, a terminal 17 is fixed in the electric
wire 1 illustrated in FIG. 1 or 2 and therefore, an electric wire
19 with a terminal is obtained.
The terminal 17 is provided with a wire barrel portion 21 and an
insulation barrel portion 23. In the electric wire 19 with the
terminal, since the wire barrel portion 21 is crimped, the wire
barrel portion 21 and the bonded portion 9 are integrated together,
and since the insulation barrel portion 23 is crimped, the
insulation barrel portion 23 and a front end of the sheath 5 are
integrated together.
A bonding method for a conductor of an electric wire according to
an embodiment of the present invention will be described below.
The bonding method for a conductor of an electric wire according to
an embodiment of the present invention is, as illustrated in FIGS.
2 to 3C, a method of ultrasonically bonding a plurality of strands
7 of an electric wire 1 to each other using an anvil 11 and a horn
13, the electric wire 1 including a conductor 3 formed of the
plurality of strands 7 and a sheath 5 covering the conductor 3 such
that the conductor 3 is exposed to a predetermined length.
In the bonding method for a conductor of an electric wire according
to an embodiment of the present invention, a part of the conductor
(exposed conductor) 3A that is exposed is clamped between the anvil
11 and the horn 13 throughout a predetermined length and the horn
13 is ultrasonically vibrated in the longitudinal direction (in the
front rear direction) of the strands 7 (conductor 3) to
ultrasonically bond the strands 7 to each other.
The ultrasonic bonding will be described in detail below.
The electric wire 1 includes, as described above, a conductor (core
wire) 3 formed by gathering a plurality of strands 7 and a sheath
(insulator) 5 covering (coating) the conductor 3.
In addition, in the electric wire 1 before the strands 7 are
ultrasonically bonded to each other, since the sheath 5 is not
present (the sheath 5 is eliminated) in a part of the electric wire
1 in the longitudinal direction (for example, one end), the
conductor 3 is exposed to a predetermined length (an exposed
conductor 3A is formed).
The strands 7 of the conductor 3 are made of metal such as copper,
aluminum, or aluminum alloy, and are formed in an elongated
cylindrical shape. The conductor 3 is formed in a form in which a
plurality of strands 7 are twisted, or a form in which a plurality
of strands 7 are arranged and extend linearly.
In addition, the cross-section of the portion of the electric wire
1 where the sheath 5 is present (cross-section taken along a plane
orthogonal to the longitudinal direction) is formed in a
predetermined shape such as a circular shape.
Although the electric wire 1 is flexible, for convenience of
description, it is assumed that the electric wire 1 extends
linearly.
The cross section of the conductor 3 at the portion of the electric
wire 1 where the sheath 5 is present is formed in a generally
circular shape because a plurality of the strands 7 are bundled in
a state of almost no gap therebetween. The cross section of the
sheath 5 at the portion of the electric wire 1 where the sheath 5
is present is formed in an annular shape with a predetermined width
(thickness). The entire of the inner circumference of the sheath 5
is in contact with the entire of the outer circumference of the
conductor 3.
Further, in the portion of the electric wire 1 where the sheath 5
is present, the strands 7 are tightened by the sheath 5 (the
strands 7 receives an urging force from the sheath 5 such that the
cross-section of the conductor 3 becomes smaller). Therefore, the
strands 7 are gathered and are integrated together in the portion
of the electric wire 1 where the sheath 5 is present, and vibration
at each of the strands 7 is rapidly reduced. The urging force by
the sheath 5 almost does not exist in a middle portion 15.
The ultrasonic bonding of the strands 7 is, as illustrated in FIG.
2 and FIGS. 3A and 3B, performed by using, for example, a grinding
jaw 25, an anvil plate 27, a horn 13, and an anvil 11.
In each of the anvil 11, the grinding jaw 25, the anvil plate 27,
and the horn 13, planes or planar portions (for example, planar
portions having fine irregularities) 29, 31, 33, 35 are formed in
the anvil 11, the grinding jaw 25, the anvil plate 27, and the horn
13, respectively.
The planar portion 31 of the grinding jaw 25 and the planar portion
33 of the anvil plate 27 are orthogonal to each other in the width
direction and face each other in parallel. The distance between the
planar portion 31 of the grinding jaw 25 and the planar portion 33
of the anvil plate 27 is adjustable through position determination
by moving at least one of the grinding jaw 25 and the anvil plate
27 in the width direction.
The planar portion 35 of the horn 13 and the planar portion 29 of
the anvil 11 are orthogonal to each other in the vertical direction
and face each other in parallel. As understood above, the planar
portion 31 of the grinding jaw 25 and the planar portion 33 of the
anvil plate 27, and the planar portion 35 of the horn 13 and the
planar portion 29 of the anvil 11 are orthogonal to each other.
The distance between the planar portion 35 of the horn 13 and the
planar portion 29 of the anvil 11 is changed by moving at least one
of the horn 13 and the anvil 11 in the vertical direction. For
example, the distance between the planar portion 35 of the horn 13
and the planar portion 29 of the anvil 11 can be changed by moving
the anvil 11 with specified force using an actuator such as an air
pressure cylinder with respect to the horn 13.
In addition, a quadrangular prism shaped space 37, both ends of
which are open in the front rear direction, is formed by the
grinding jaw 25, the anvil plate 27, the horn 13, and the anvil 11.
The quadrangular prism shaped space 37 is surrounded by the planar
portion 31 of the grinding jaw 25, the planar portion 33 of the
anvil plate 27, the planar portion 35 of the horn 13, and the
planar portion 29 of the anvil 11.
When ultrasonic bonding is performed, a conductor 3A which is
exposed (exposed conductor) is inserted into the quadrangular prism
shaped space 37 such that the longitudinal direction of the strands
7 coincides with the front rear direction of the quadrangular prism
shaped space 37.
That is, when ultrasonic bonding is performed, the exposed
conductor 3A is inserted into the quadrangular prism shaped space
37 such that the longitudinal direction of the strands 7 is
parallel with the planar portion 31 of the grinding jaw 25, the
planar portion 33 of the anvil plate 27, the planar portion 35 of
the horn 13, and the planar portion 29 of the anvil 11 (becomes the
front rear direction).
In a state where the strands 7 of the exposed conductor 3A are
inserted into the quadrangular prism shaped space 37, the
ultrasonic bonding of the strands 7 is made by moving the anvil 11
toward the horn 13 to press the strands 7 with the anvil 11 and the
horn 13 and at the same time, ultrasonically vibrating the horn 13.
By ultrasonically bonding the strands 7, inserted into the
quadrangular prism shaped space 37, to each other, a bonded portion
9 with a predetermined length is formed in a part of the exposed
conductor 3A in the longitudinal direction.
The vibration direction of the horn 13 at the time of ultrasonic
bonding is, for example, the front rear direction (the longitudinal
direction of the strands 7). Furthermore, since the strands 7 are
pressed with the anvil 11 and the horn 13, the planar portion 31 of
the grinding jaw 25 and the planar portion 33 of the anvil plate 27
receive the pressing force from the strands 7.
In the case of ultrasonic bonding, the distance x between the anvil
11 and the horn 13 (more precisely, an end of the exposed conductor
3A, clamped between the anvil 11 and the horn 13, on the side of
the sheath 5) and the sheath 5 of the electric wire 1 (see FIG. 2)
is shorter than a length L in a case where the strand 7 is vibrated
in the primary mode (a length in a case where vibration is
generated in the primary mode at a single strand 7 due to the
ultrasonic vibration of the horn 13) (x<L).
The above-mentioned length L may be expressed by the formula f1
described below.
.function..times..pi..times..times..times..rho..times..times.
##EQU00001## The formula f1 is a formula showing a primary
vibration mode of a strand in a middle portion of a conductor of an
electric wire according to an embodiment of the present invention;
In the formula f1, "m" is a constant, and a value thereof is
"4.730". In the formula f1, "f" is an ultrasonic frequency (the
frequency of the horn 13), and its unit is "Hz".
In the formula f1, ".rho." is the density of the strands 7, and its
unit is "kg/m.sup.3". In the formula f1, "A" is the cross-sectional
area of a single strand 7 (the area of a cross-section taken along
a plane orthogonal to the longitudinal direction), and its unit is
"m.sup.2". In the formula f1, "E" is the Young's modulus of the
strand 7 (longitudinal elastic modulus), and its unit is
"N/m.sup.2". In the formula f1, "I" is the cross-sectional
secondary moment of a single strand 7, and its unit is
"m.sup.4".
On the other hand, in the electric wire 1 illustrated in FIG. 1 or
2, the outer diameter of a middle portion 15 of the conductor 3
positioned between the bonded portion 9 formed by ultrasonic
bonding and a portion covered by the sheath 5 (a portion of the
conductor 3 positioned between the bonded portion 9 and the sheath
5 in the front rear direction) gradually decreases from the portion
covered by the sheath 5 toward the bonded portion 9 (from the rear
side toward the front side), as described above.
In addition, in the electric wire 1, the maximum value .theta. of
the intersection angle between the longitudinal direction (the
front rear direction) of the electric wire 1 and the strands 7 of
the middle portion 15 of the conductor 3 is smaller than a
predetermined angle .theta.a (.theta.<.theta.a).
The predetermined angle (breakage prevention angle) .theta.a is an
angle at which breakage of all the strands 7 in the middle portion
15 can be prevented when the ultrasonic bonding is performed (when
the ultrasonic bonding is performed or when the ultrasonic bonding
is completed).
In addition, the predetermined angle .theta.a is an angle at which
all the strands 7 in the middle portion 15 does not cause fatigue
fracture by a load applied to the strands 7 due to compression of
the strands 7 at the bonded portion 9 and ultrasonic vibration when
the ultrasonic bonding is performed or when the ultrasonic bonding
is completed.
The fatigue fracture is caused by the fluctuation load (repeated
load) applied to the strands 7 of the middle portion 15 and a
static load applied to the strands 7 of the middle portion 15 and
is, for example, fracture of the strands 7 in the middle portion
15.
The fluctuation load is a load (for example, a vibration load)
applied to the strands 7 of the middle portion 15 due to the
vibration of the horn 13 at the time of ultrasonic bonding. The
repeated stress is caused in the strands 7 of the middle portion 15
due to the fluctuation load.
Since the strands 7 are vibrated similarly by the vibration of the
horn 13, values of the repeated stress occurring in the respective
strands 7 are almost equal to each other.
When the fracture of the strands 7 due to only the fluctuation load
is defined as pure fatigue fracture, it is determined whether or
not pure fatigue fracture occurs depending on forms of repeated
stress occurring in the strands 7 by ultrasonic bonding (a force
for clamping a plurality of strands 7 between the anvil 11 and the
horn 13, a vibration frequency of the horn 13, an amplitude of the
horn 13, etc.), a time during which the repeated stress occurs in
the strands 7 due to the ultrasonic bonding, a material of the
strands 7, and the like.
The static load is a load applied to the strands 7 of the middle
portion 15 as the outer diameter of the middle portion 15 of the
conductor 3 gradually decreases from the rear side toward the front
side. The static load is not generated in a state before the
strands 7 (conductor 3) are clamped between the anvil 11 and the
horn 13 (for example, see FIG. 3A).
In the state before the strands 7 are clamped between the anvil 11
and the horn 13 (for example, see FIG. 2), and the horn 13 starts
to be vibrated, a distance between the anvil 11 and the horn 13 (a
distance in the vertical direction) is smaller than the outer
diameter d3 of the portion covered with the sheath 5 of the
conductor 3.
Therefore, most of the strands 7 of the middle portion 15 stretches
out obliquely. Each of the strands 7 extends except a part (except
a part extending along the central axis C1), and distortion in each
of the strands 7 occurs, resulting in occurrence of static stress
in most of the strands 7.
Thereafter, when ultrasonic vibration is performed on the horn 13,
bonding of the strands 7 is made and the bonded portion 9 is then
formed. In this case, the distance between the anvil 11 and the
horn 13 (the distance in the vertical direction) gradually
decreases and the shape of the middle portion 15 is gradually
changed.
As a result, the values of the static stress in the respective
strands 7 gradually increase, and as illustrated in FIG. 2, a
height dimension of the bonded portion 9 becomes "d2" and, when the
ultrasonic bonding is completed, the height dimension reaches the
maximum.
Although the values of the above-mentioned repeated stress are
almost the same with respect to the respective strands 7 in the
middle portion 15, the values of the static stress are different
depending on the positions of the strands 7 in the middle portion
15.
For example, the value of the repeated stress of the strands 7
positioned at the central axis C1 and the value of the repeated
stress of the strands 7 positioned in an outer peripheral surface
15A are almost equal to each other. In contrast, the value of the
static stress of the strands 7 positioned at the central axis C1 is
almost "0", and static stress occurs in the strands 7 positioned in
the outer peripheral surface 15A. The value of the static stress
increases as the value of the intersection angle of the strand 7
with respect to the front rear direction increases.
Therefore, the static stress occurring in the strand 7 varies
depending on a shape of the middle portion 15, diameters of the
strands 7, positions of the strands 7 constituting the middle
portion 15, and the like.
When the fracture of the strand 7 due to the static load alone is
considered in the formation of the bonded portion 9 using the anvil
11 and the horn 13, only an intersection angle .theta.b of a strand
7 in which the value of the intersection angle with respect to the
front rear direction is the maximum can be considered after the
formation of the bonded portion 9.
The intersection angle .theta.b can be calculated by the formula
f2; .theta.b=cos-1 (1/(1+.epsilon.)). Here, ".epsilon." indicates a
distortion of the strand 7 having the maximum value of the
intersection angle with respect to the front rear direction (for
example, the strand positioned in the outer peripheral surface 15A
of the middle portion 15 illustrated in FIG. 2).
Also, ".epsilon." can also be expressed by the dimension a, shown
in FIG. 2 or 3, and the dimension b shown in FIG. 2. That is,
.epsilon.=(b-a)/a.
In FIG. 2, the static stress .sigma.s of the strand 7 positioned in
the outer peripheral surface 15A is given by the formula f3;
.sigma.s=.epsilon.E. "E" is the longitudinal elastic modulus of the
strand 7.
Since the fatigue fracture of the strand 7 needs to be considered
in conjunction with the pure fatigue fracture of the strand 7 and
the fracture due to the static load of the strand 7, the
above-mentioned predetermined intersection angle .theta.a is
smaller than the intersection angle .theta.b for avoiding fracture
caused by the static load alone.
Therefore, a relationship of the maximum value of the intersection
angle .theta. illustrated in FIG. 2<the predetermined
intersection angle .theta.a<the intersection angle .theta.b for
avoiding fracture caused by the static load alone is
established.
The difference between the intersection angle .theta.b and the
intersection angle .theta.a is determined by a type of the
ultrasonic bonding, such as the vibration frequency of the horn 13,
as understood already.
The intersection angle between the front rear direction and the
strand 7 will be further described below.
When the bonded portion 9, the middle portion 15 and the portion
covered with sheath 5 in electric wire 1 illustrated in FIG. 1 or 2
is viewed from a direction (a vertical direction, a width
direction, or an oblique direction with respect to the vertical
direction and the width direction) orthogonal to an extending
direction (the longitudinal direction of the electric wire 1) of
the central axis C1 of the electric wire 1, most of a plurality of
strands 7 intersect at predetermined angles with respect to the
longitudinal direction of the electric wire 1 (the front rear
direction) in the middle portions 15 as described above. As
described above, the values of the intersection angles of the
plurality of strands 7 are different from each other.
Here, the intersection angle will be described for sure. Generally,
there are two intersection angles as the intersection angle of two
straight lines on the plane. The sum of these two intersection
angles is 180.degree.. One angle of the two intersection angles is
an acute angle and the other intersection angle is an obtuse angle.
The intersection angle .theta. (.theta.a, .theta.b) in the present
specification is the smaller one of the two intersection angles
(acute angle) as already understood.
The intersection angle varies depending on the angle at which the
electric wire 1 is viewed. For example, when the strands 7
positioned in the outer peripheral surface 15A of the middle
portion 15 are viewed in the width direction, the intersection
angle becomes ".theta." as illustrated in FIG. 2, and, when the
strands 7 positioned in the outer peripheral surface 15A of the
middle portion 15 are viewed in the vertical direction, the
intersection angle becomes "0.degree.".
In the case where the strands 7 are not twisted, the strands 7 are
parallel to each other and extend in the longitudinal direction of
the electric wire 1 in the portion of the conductor 3 covered with
the sheath 5. In addition, when the strands 7 are not twisted, the
maximum of the intersection angle is indicated by reference symbol
".theta." in FIG. 2.
Although the intersection angle of the strands 7 position in the
outer peripheral surface 15A of the middle portion 15 is largest in
the above description, the intersection angle of the strands 7
positioned in ridge lines 15B of the middle portion 15 illustrated
in FIG. 1 or other strands may be the largest.
In the above description, the strands 7 are not twisted, and
therefore, the intersection angle is caught two-dimensionally, but,
in a case where the strands 7 are twisted, the intersection angle
may be caught three-dimensionally by considering the twisting of
the strands 7.
Although the bonded portion 9 is formed in a rectangular shape in
the above description, the bonded portion 9 may be formed in a
cylindrical shape as illustrated in FIG. 6. In addition, the
cross-sectional shape of the portion of the conductor 3 covered
with the sheath 5 may have another shape such as a rectangular
shape.
Furthermore, in the above description, although, when ultrasonic
bonding is performed, as illustrated in FIG. 2, the position of the
front end of the conductor 3 of the electric wire 1 and the
position of the front end of the anvil 11 and the horn 13 coincide
with each other in the front-rear direction, the front end of the
conductor 3 of the electric wire 1 may be positioned on the front
side than the front ends of the anvil 11 and the horn 13, or may be
positioned on the rear side, as illustrated in FIG. 5.
On the other hand, when ultrasonic bonding of the conductor 3 of
the electric wire 1 is performed using the anvil 11 and the horn
13, as illustrated in FIGS. 2, 3A and 3C, the sheath 5 of the
electric wire 1 is clamped by a sheath holding part 39 having a
pair of clampers 41.
In this case, the distance L1 between the pair of clampers 41 and
the front end of the sheath 5 is appropriately determined. The
distance L1 may be set to "0", or the value of the distance L1 may
be smaller or larger than the value of the outer diameter d4 of the
electric wire 1 (the sheath 5).
Furthermore, as illustrated in FIGS. 10A and 10B, the anvil 11 and
the horn 13 may be provided with an inclined surface 43. The
inclined surface 43 is formed in such a manner that the
above-mentioned angle .theta. is formed at a portion of the middle
portion 15 of the conductor 3 of the electric wire 1 on the side of
the bonded portion 9 and is in contact with the conductor 3 over a
predetermined length.
Although the bonded portion 9 is formed at one end in the
longitudinal direction of one electric wire 1 in the above
description, as illustrated in FIGS. 9A and 9B, the bonded portion
9 is formed at the middle portion of one electric wire 1 in the
longitudinal direction.
As illustrated in FIGS. 7A to 8B, strands 7 of conductors 3 of a
plurality of electric wires (for example, two electric wires) 1 may
be ultrasonically bonded to each other to form one bonded portion
9.
In the embodiment illustrated in FIGS. 7A and 7B, by forming the
bonded portion 9 at an end of one electric wire 1 (1a) and an end
of the other electric wire 1 (1b), the electric wire 1a and the
electric wire 1b are connected in series, so that the electric wire
1b is connected to the electric wire 1a at the bonded portion 9,
and the electric wire 1a and the electric wire 1b extends in a
single straight line.
In the embodiment illustrated in FIGS. 8A and 8B, by forming the
bonded portion 9 at an end of one electric wire 1 (1a) and an end
of the other electric wire 1 (1b), the electric wire 1a and the
electric wire 1b are connected in parallel so that the electric
wire 1a and the electric wire 1b extends in parallel from the
bonded portion 9.
On the other hand, in the ultrasonic bonding of the conductor 3 of
the electric wire 1, the bonding state of the bonded portion 9 may
be inspected after the bonded portion 9 has been formed.
The inspection for the bonding state of the bonded portion 9 is
performed in other to determine whether or not a strand (straggling
strand) 7A that is not bonded to the bonded portion 9 exists, and
as illustrated in FIGS. 11A to 14, the inspection is made by
allowing a fluid (for example, air) to flow to the bonded portion 9
at a flow rate exceeding a predetermined speed.
More specifically, the inspection for the bonding state of the
bonded portion 9 is performed, as illustrated in FIGS. 11A and 11B,
and FIGS. 12A and 12B, by blowing compressed air of a predetermined
pressure toward the bonded portion (see the arrow) from an ejection
port (an ejection port with a predetermined inner diameter) of a
jet nozzle (not illustrated) spaced apart from the bonded portion 9
by a predetermined distance.
In the embodiment illustrated in FIGS. 11A and 11B, the jet nozzle
is arranged on the front side than the front end of the bonded
portion 9 of the electric wire 1, and the compressed air is jetted
to the rear side from the jet nozzle for a predetermined time and
is then brown to the bonded portion 9 positioned on the rear side
of the jet nozzle.
FIG. 11A illustrates a state before compressed air is blown, and
FIG. 11B illustrates a state after compressed air is blown.
In FIG. 11A, a strand 7A that is not bonded to the bonded portion 9
substantially sticks to the bonded portion 9, and it is difficult
to determine whether or not the strand 7A that is not bonded to the
bonded portion 9 exist with the naked eye (visual inspection by
visual observation).
In this regard, in FIG. 11B, the strand 7A that is not bonded to
the bonded portion 9 is deformed by the compressed air and is
separated from the bonded portion 9 so that it is possible to
easily determine whether or not the strand 7A that is not bonded to
the bonded portion 9 exist even with the naked eye.
In the embodiment illustrated in FIGS. 12A and 12B, the jet nozzle
is arranged on the lateral side of the bonded portion 9, and the
compressed air is blown toward the bonded portion 9 from the
direction (for example, width direction) orthogonal to the
longitudinal direction (the front rear direction) of the electric
wire 1 for a predetermined time.
FIGS. 12A and 12B illustrate a state after compressed air is blown,
and in FIGS. 12A and 12B, the strand 7A that is not bonded to the
bonded portion 9 is deformed by the compressed air and is separated
from the bonded portion 9 so that it is possible to easily
determine whether or not the strand 7A that is not bonded to the
bonded portion 9 exist even with the naked eye.
In addition, the inspection for the bonding state of the bonded
portion 9 may be performed, as illustrated in FIGS. 13A and 13B, by
sucking air by a suction port (a suction port with a predetermined
inner diameter) of a suction nozzle (not illustrated) spaced apart
from the bonded portion 9 by a predetermined distance at a
predetermined flow rate (see the arrow).
In the embodiment illustrated in FIGS. 13A and 13B, suction nozzles
are arranged on the lower side and the upper side of the bonded
portion 9 to suck air from the lower side and the upper side of the
bonded portion 9. In FIGS. 13A and 13B, what are indicated by
reference numeral 7A are the strands 7A that are not bonded to the
bonded portion 9 and are separated from the bonded portion 9.
In the embodiments illustrated in FIGS. 12 to 14, in order to
inspect the whole of the bonded portion 9 all over, it may be
possible that the jet nozzle and the suction nozzle is relatively
moved or rotated (rotation in the case of the bonded portion 9,
revolution in the case of the nozzle) with respect to the bonded
portion 9 (electric wire 1), and the compressed air is blown or the
air is sucked.
In addition, air may be blown or sucked by the nozzle
intermittently. For example, the flow of air may be turned on and
off every second.
Further, the bonding state of the bonded portion 9 may be inspected
by applying an acceleration exceeding a predetermined magnitude to
the bonded portion 9 as illustrated in FIGS. 14A and 14B.
In the embodiment illustrated in FIGS. 14A and 14B, the strand 7A
that is not bonded to the bonded portion 9 is separated from the
bonded portion 9 by centrifugal force generated when the bonded
portion 9 is rotated around the central axis C1 at a speed equal to
or higher than a predetermined rotation speed.
Instead of or in addition to rotating of the bonded portion 9, by
performing shaking of the bonded portion 9 or the like, the strands
7 may be separated from the bonded portion 9 by inertial force of
the strand 7A that are not bonded to the bonded portion 9.
Further, after the bonded portion 9 is formed, by performing at
least one (for example both) of: allowing a fluid having a flow
rate exceeding a predetermined speed to flow to the bonded portion
9; and applying an acceleration exceeding a predetermined magnitude
to the bonded portion 9, the bonding state of the bonded portion 9
may be inspected.
Further, after the strand 7A that is not bonded to the bonded
portion 9 is separated from the bonded portion 9, inspection may be
performed not by visual inspection but by an inspection apparatus
having an imaging part, an image processing part, a memory, or a
CPU. That is, after the strand 7A that is not bonded to the bonded
portion 9 is separated from the bonded portion 9, the bonded
portion 9 and the strand 7A are photographed by the imaging part,
and the photographed image data is processed by the image
processing part, and the strand 7A that is not bonded to the bonded
portion 9 may be detected.
In addition, by allowing a fluid having a flow rate exceeding a
predetermined speed to flow to the middle portion 15 or applying an
acceleration exceeding a predetermined magnitude to the middle
portion 15, the strand breakage occurring in the middle portion 15
may be inspected.
According to the electric wire 1, since a distance from the anvil
11 or the horn 13 to the sheath 5 of the electric wire 1 is shorter
than a length of the strands 7 when the strand 7 vibrates in the
primary mode by ultrasonic vibration, the vibration of the strand 7
is effectively suppressed and a specific portion cannot be
subjected to repeated stress, thereby preventing occurrence of
strand breakage when ultrasonic bonding is performed.
Further, according to the electric wire 1, the maximum value
.theta. of the intersection angle between the longitudinal
direction of the electric wire 1 and the strand 7 in the middle
portion 15 of the conductor 3 is smaller than the predetermined
angle .theta.a, and the predetermined angle .theta.a is an angle at
which all of the strands 7 of the middle portion 15 can be
prevented from being broken at the time of ultrasonic bonding,
thereby preventing occurrence of strand breakage when ultrasonic
bonding is performed.
Further, according to the electric wire 1, the maximum value
.theta. of the intersection angle between the longitudinal
direction of the electric wire 1 and the strand 7 in the middle
portion 15 of the conductor 3 is smaller than the predetermined
angle .theta.a, and the predetermined angle .theta.a is an angle at
which fatigue fracture cannot be caused in all of the strands 7 of
the middle portion 15 at the time of ultrasonic bonding, thereby
more reliably preventing occurrence of strand breakage at the time
of ultrasonic bonding.
Further, according to the electric wire 1, since the inclined
surface 43 is formed on the anvil 11 and the horn 13, a portion of
the middle portion 15 on the side of the bonded portion 9 is also
clamped between the anvil 11 and the horn 13 appropriately when
ultrasonic bonding is performed. As a result, it is possible to
accurately hold the boundary between the bonded portion 9 and the
middle portion 15 and the vicinity thereof and to suppress
occurrence of stress concentration in the strand 7 in the boundary
between the bonded portion 9 and the middle portion 15.
Further, according to the electric wire 1, after the bonded portion
9 is formed, by allowing a fluid having a flow rate exceeding a
predetermined speed to flow into the bonded portion 9 or applying
an acceleration exceeding a predetermined magnitude to the bonded
portion 9, it is possible to easily discover a strand 7 that does
not form the bonded portion 9 with the naked eye.
That is, only when the bonded portion 9 is simply formed, it seems
like that the strand 7 that is not bonded to the bonded portion 9
also extend in the front rear direction in a manner that it sticks
to the bonded portion 9 and is integrated with the bonded portion
9.
However, by allowing a fluid having a flow rate exceeding a certain
speed to flow to the bonded portion 9 or applying an acceleration
exceeding a predetermined magnitude to the bonded portion 9, a
strand (for example, one strand which exists alone) 7A that does
not form the bonded portion 9 is separated from the bonded portion
9 and stretches out. As a result, the strand 7A that is not bonded
to the bonded portion 9 can be easily found with the naked eye, and
defective products can be eliminated.
Further, according to the electric wire 1, since a part of the
sheath 5 is held when ultrasonic bonding of the strands 7 is
performed, it is possible to reliably prevent the strands 7 from
being vibrated in the portion of the conductor 3 covered with the
sheath 5 and to precisely secure the length x of the middle portion
15, thereby more reliably preventing occurrence of strand breakage
at the time of ultrasonic bonding.
Although the bonded portion 9 is formed by ultrasonic bonding in
the above description, the bonded portion 9 may be formed by other
treatments than the ultrasonic treatment, such as cold welding,
friction stir welding, friction welding, electromagnetic welding,
diffusion welding, brazing, soldering, resistance welding, electron
beam welding, laser welding, and light beam welding.
* * * * *